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Nk-Wur-Pep-Mep-003 Material Excution Plan
Nk-Wur-Pep-Mep-003 Material Excution Plan
Nk-Wur-Pep-Mep-003 Material Excution Plan
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PROJECT CONTROL PLAN
ISSUED BY : Project Control Superintendet Rev. 0
DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 3 of 38
Area / Dept : PHR All Area - OU
LEMBAR REVISON
DOKUMEN REF : NK-WUR-PEP-MEP-003
0
PROJECT CONTROL PLAN
ISSUED BY : Project Control Superintendet Rev. 0
DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 4 of 38
Area / Dept : PHR All Area - OU
DAFTAR ISI
1. INTRODUCTION ................................................................................................................................................... 5
2. MATERIAL TEAM ORGANIZATION CHART ........................................................................................................... 6
3. CLIENT MATERIAL PREPARATION PROCESS......................................................................................................... 7
4. MATERIAL EXECUTION PROCESS ....................................................................................................................... 14
4.1. Client Provided Material Request Process ..................................................................................................... 14
4.2. Client Provided Material Request Process for Maintenance Work ................................................................ 18
4.3. Material Withdraw Process........................................................................................................................... 22
4.4. Material Utilization Reporting Process .......................................................................................................... 27
5. PARTIAL / FINAL MATERIAL INVENTORY ........................................................................................................... 31
PROJECT CONTROL PLAN
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DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 5 of 38
Area / Dept : PHR All Area - OU
1. INTRODUCTION
This Material Execution Plan is provided as a guidance for material planning and controlling within CS WUR
EW – General Paket 3 contract.
Project Manager
Deputy PC Supt
Material Supv
Material Admin
Material team will work directly under Deputy Project control superintendent and Construction
Manager will have indirect command (dotted) line with material team which involve in system
management & implementation and personnel performance evaluation.
The scope of this process is to prepare client’s material utilization plan. After receiving bill of material
(BoM), construction engineer shall compare Material Requirement with Approve For Construction
(AFC) drawing to identify the actual required material. After that, material team shall check the
availability of the material that provided by the client. If the availability is less than 90%, client shall be
notified and SPK is proposed to be returned.
If the material withdraw need to be schedule (depend on client’s requirement), construction engineer
shall provide material schedule that will be used as guideline for all team.
Executor
Construction Engineer, responsible to evaluate the actual material requirement to execute the work
request.
Material Team, responsible to prepare material request to client and check the material availability
at CPI Warehouse
SPK Owner, responsible to provide bill of material (BoM) and ensure the availability of material on
time
Forms
Start
PC1.2
Send request to
Provide BoM No BoM available?
SR owner
MR1.1.1
MR1.1.3 MR1.1.2
Yes
Compare BOM to
the drawing
MR1.1.4
.
PC2.3 Need
Yes
additional?
MR1.1.5
No Yes
Start
B
A
PROJECT CONTROL PLAN
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Area / Dept : PHR All Area - OU
Construction Engineer Document Control Project Control Construction PIC Material Team
MR1.1.11 MR1.1.12
MR2.1 MR2.1
End
MR1.1.16
End
MR1.1.1 After receiving work request package, construction engineer shall check the
availability of bill of material.
BoM available?
• If BoM available, go to MR1.1.4
• If BoM is not available, go to MR1.1.2
Construction
Engineer
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Area / Dept : PHR All Area - OU
Send request to SPK • Send request for bill of material to SPK owner for the specific work
owner request
Construction
Engineer
Provide BoM • Provide bill of material for the specific work request
SPK Owner
Compare BoM to the • Construction drawing shall be the main reference to identify the material
drawing requirement
• Check the bill of material and compare it to construction drawing
• Separate material that shall be provided by contractor and work request
owner
• Identify any additional material that is not captured in the original bill of
material
• For work unit rate type of work request, construction engineer shall
match the material requirement with the available work unit rate and
inform project control if there is un-match condition.
Construction
Engineer
Construction
Engineer
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Area / Dept : PHR All Area - OU
Construction
Engineer
Check material • Material team check the availability of material that provided by the
availability status client (warehouse and the system)
Material Team
Inform material • Inform the availability percentage status of the required material
availability status
SPK Owner
Material Team
Construction
Engineer
PROJECT CONTROL PLAN
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DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 12 of 38
Area / Dept : PHR All Area - OU
Construction
Engineer
File and distribute to Distribute material schedule and material cutting plan to project team
project team
• File material schedule and material cutting plan as archive
• Distribute material schedule and material cutting plan to respective
project team
Document Control
Integrate with work • Integrate material schedule with work request schedule
request schedule • Monitor material availability progress
Project Control
Use material • Construction Supv and the team will use material schedule as reference to
schedule as reference plan material requirement and request.
Construction Supv
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Area / Dept : PHR All Area - OU
Use material • Material team use material schedule as reference to plan material
schedule as reference delivery after actual request from construction team
Material Team
Send SPK return • If material availability is less than 90%, work request cannot be executed
notification to SPK • Send notification to SPK owner about the condition and propose to return
Owner the SPK
Project Control
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Area / Dept : PHR All Area - OU
Material preparation that has been developed in MR1.1 will be used as baseline for material request
process that initiated by construction team. If the requested material exceeds the plan, approval from
NK construction engineer is required. If the requested material is additional item, then a material
change proposal shall be obtained first. After that, material team will forward the material request to
the SPK owner or representative for approval process.
Executor
Construction Supv, responsible to review the material schedule and submit material request
Material Team, responsible to verify all material requests based on the agreed material schedule
Construction Engineer, responsible to review approval for material request that exceed the schedule.
SPK Owner, responsible to review and give approval for requested materials that are provided by the
client.
Forms
Start
MR1.1
No
Review material
Schedule OK?
schedule
MR2.1.2
MR2.1.1
Yes
Prepare material
request No
(hardcopy)
MR2.1.3
Verifiy request
Submit material
with BOM and
request
material schedule
MR2.1.4 MR2.1.5
Approved
Additional MR1.1.4
Yes change No
item?
available?
MR2.1.6 MR2.1.7
Yes
Request
No Yes Approve?
exceed plan?
MR2.1.8 MR2.1.9
No
Material
Submit material
Request Yes
request
Approval
MR2.1.10
MR2.2
End
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Area / Dept : PHR All Area - OU
Construction Supv
Construction Supv
Verify request with • Compare the material request base on bill of material and material
BOM and material schedule
schedule
Material Team
MR2.1.4 • If there is additional item in the request, material team shall ensure the
availability of approved material change proposal (MR2.1.5)
Additional item?
• If all items are listed in the original BoM, continue to MR2.1.6
Material Team
MR2.1.5 • If the approved material change proposal is available for the related
items, continue to MR2.1.6
Approved change • If there is no approved material change proposal, inform the construction
available? engineer to continue the process (MR1.1.4)
Material Team
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Area / Dept : PHR All Area - OU
MR2.1.6 • If the requested quantity or material item exceeds the plan, continue to
MR2.1.7
Request exceed plan?
• If not, continue to MR2.1.8
Material Team
Construction Engineer
Submit material • Submit material request complete with supporting document such as
request o Material schedule
o Copy of approved material change proposal (if required)
• After approval process from SPK owner or the representative, the
Material Team process is continued to MR2.2
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DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 18 of 38
Area / Dept : PHR All Area - OU
For several projects type, the client might assign SPK for facility maintenance or emergency condition
which is not planned yet. This type of work has no bill of material and therefore the project team shall
conduct site visit process to identify the scope of work include required material to execute the
request (MR2.4)
Based on the site visit result, construction team will submit material request through material team.
Executor
Construction Supv, responsible to review the maintenance SPK and submit material request
SPK Owner, responsible to review and give approval for requested materials that are provided by
the client.
Forms
References
PROJECT CONTROL PLAN
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Area / Dept : PHR All Area - OU
Start
Receive PC1.4
Maintenance Site visit
Order
MR2.2.1
MR2.2.3 MR2.2.2
Submit material
Verifiy request
request
MR2.2.4 MR2.2.5
Material
Submit material
Request
request
Approval
MR2.2.6
MR2.3
End
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Area / Dept : PHR All Area - OU
Construction Supv
Identify required • List down all required material to execute the work based on site visit
material to execute the process (PC1.4)
work
Construction Team
Construction Team
Construction Team
Verify request • Check and verify material request that is submitted by the
construction
Material Team
PROJECT CONTROL PLAN
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Area / Dept : PHR All Area - OU
Note:
Material Team After approval from SPK owner, the process is continued to MR2.3
PROJECT CONTROL PLAN
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Area / Dept : PHR All Area - OU
After the material request is approved, material team withdraws the material, delivers into
contractor’s warehouse and informs the availability to construction team so that construction team
can pick the material and deliver to work site. The in and out material activities must be completed
with the supporting document.
Executor
Material Team, responsible to withdraw material from client’s warehouse, delivers to contractor’s
warehouse and informs the construction team
Construction Supv, responsible to pick the available requested material and delivers to work site
Forms
References
Start
MR2.3.1
Record And
update material
receive
MR2.3.2
Inform material
Prepare material
Material availability to the
issue form
Database construction team
MR2.3.3 MR2.3.4
Ensure material
issue match the
request
MR2.3.5
End
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Area / Dept : PHR All Area - OU
Withdraw material • Compare the material request with the available list to be withdrawn.
from client’s • Put note to be followed up later for item that is not available yet.
warehouse • Ensure materials are in good condition
• Fill in the client’s withdraw material form
• Withdraw material and delivers to contractor’s warehouse
Material Team
Material Team
Material Team
PROJECT CONTROL PLAN
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Area / Dept : PHR All Area - OU
Prepare material issue • Check and ensure the materials are in good condition
form • Prepare and fill in material issue form with clear information about
o Material Request No
o SPK No
o Other identification
o List of material
Construction Supv
Update material stock • Update material stock card for the related materials that were issued
card from warehouse.
• Update daily material transaction (in – out)
Note:
Material Team
Construction Supv
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Area / Dept : PHR All Area - OU
Note:
Material Team
Construction Supv
PROJECT CONTROL PLAN
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DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 27 of 38
Area / Dept : PHR All Area - OU
Construction team shall report all material that has been installed / utilized for the SPK. This process
is to ensure that the requested/withdrawn materials are installed or used for the right SPK and to ease
the closing report at the end of work execution.
It is not allowed to transfer or use materials that are not belong or registered for the SPK without
proper approval from authorized person both in contractor and SPK owner.
Executor
Material Team, responsible to monitor material utilization and update material database
Forms
References
Start
MR2.3
Record and
Utilize material update material Material
utilization Database
MR2.4.1 MR2.4.2
Check material
stock and
schedule
MR2.4.3
Yes
MR2.1
Stock Check and update
No MR2.2
available? material database
MR2.4.4
MR2.4.5
End
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Area / Dept : PHR All Area - OU
Utilize material • Utilize material according to work plan and material request.
• There is two categories for material that has been utilized:
o Fabrication phase (stringing, cutting, fitting, double joint, etc)
o Installation phase (install at work site)
Construction Supv
Record and update • Record all utilization of material separately between fabrication or
material utilization already installed complete with information
o Material Request No
o SPK number
Construction Supv o Other Identification
o Location
• Update utilization status into material database
Check and update • Regularly check material database to monitor update for material
material database utilization by Construction Supv
• Remind Construction Supv for updating the database
• If there is discrepancy between material installed, BoM and request,
immediately inform construction engineer to check the possibilities
of:
o Unauthorized material transfer (SPKong install, utilize other
SPK’s material stock)
o Requirement for material change of scope (installed > BoM)
o Material surplus (installed < BoM)
Material Team
PROJECT CONTROL PLAN
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DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 30 of 38
Area / Dept : PHR All Area - OU
Construction Supv
Check and update • Regularly check material database to monitor update for material
material database utilization by Construction Supv
• Remind Construction Supv for updating the database
• If there is discrepancy between material installed, BoM and request,
immediately inform construction engineer to check the possibilities
of:
o Unauthorized material transfer (wrong install, utilize other
SPK’s material stock)
o Requirement for material change of scope (installed > BoM)
o Material surplus (installed < BoM)
Material Team
PROJECT CONTROL PLAN
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DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 31 of 38
Area / Dept : PHR All Area - OU
All materials that have been utilized shall be inventoried after the work or part of the work has
completed. This process is to ensure the balancing between withdrawn material, install and excess
material. And all excess material shall be returned to client’s warehouse (it is not allowed to utilize
excess material to other work without proper approval).
For several SPKs that have large scope of work, it is advised to conduct partial material inventory based
on completed work.
After material inventory completed, contractor shall obtain Material Completion Report/Material
Inventory Sheet that will be used as attachment to SPK close out documentation.
Executor
Material Team, responsible to monitor material utilization and update material database
SPK Owner/representative, responsible to review material inventory result and issue material
completion report
Forms
References
Start
Material data
Material change of scope
Material transfer
Drawing/BOM
Execute Surat QS Data
Perintah Kerja
MR3.1.1
No
Material
Invite for join
utilization Yes Accept invitation
inventory
report OK?
MR3.1.4
MR3.1.7 MR3.1.8
MR3.1.9 MR3.1.10
No
Review and
Prepare material
approve material
completion report
completion report
MR3.1.15 MR3.1.16
Update material
database
MR3.1.17
End
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Area / Dept : PHR All Area - OU
Construction
MR3.1.2 Construction Supv shall check when part of work or the whole work has
been completed in field
Partial/Final Work
completed? • If part or whole work is completed, go to MR3.1.3
• If work is still on progress, continue to execute the work (MR3.1.1)
Construction
Construction Supv
Material Team
PROJECT CONTROL PLAN
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Area / Dept : PHR All Area - OU
Material Team
Prepare document for • Prepare required documents for join material inventory:
join inventory o Bill of material
o Approved material change of scope (if required)
o List of withdrawn material
o List of installed material
o List of excess material
o Material transfer form (transfer in and out)
o Sketch drawing from actual work
o Quantity survey data
Material Team
Invite for join inventory • Send invitation to SPK owner or representative to conduct/witness
material inventory on site
Material team
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Area / Dept : PHR All Area - OU
Accept invitation • SPK Owner or representative will review the invitation and inform the
schedule to conduct join material inventory on site
SPK Owner
Conduct inventory • Prepare all required permit to conduct join material inventory on site
• Conduct material inventory on site
Material Team
Witness inventory • Witness join material inventory to verify installed material on site
SPK Owner
Material Team
SPK
Owner/Representative
PROJECT CONTROL PLAN
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Area / Dept : PHR All Area - OU
Material Team
SPK
owner/representative
MR3.1.15 Any material discrepancies are verified and justified with supporting
documents
Verify discrepancy
material with • Material team receive and verify material discrepancy list
supporting documents • Prepare and submit justification to SPK owner or representative
complete with supporting documents such as : Inter Go-down
transfers, emails, drawings, etc.
Material Team
Verify and validate • Check supporting documents, verify and validate to respective user
supporting documents
SPK Owner
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Area / Dept : PHR All Area - OU
MR3.1.18 Any material discrepancies are verified and justified with supporting
documents
Verify material
discrepancy with • Material team receive and verify material discrepancy list
supporting documents • Prepare and submit justification to SPK owner or representative
complete with supporting documents
Material Team
SPK
owner/representative
Prepare Back charge If, after verifying the final material discrepancy justification, there’s still
material discrepancy SPK owner will prepare and inform CS Material
Team Material Back Charge documents to be approved by CS and SPK
SPK owner.
owner/representative
PROJECT CONTROL PLAN
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DOC NO. : NK-WUR-PEP-MEP-003 MATERIAL EXECUTION PLAN Page 38 of 38
Area / Dept : PHR All Area - OU
Prepare Material • Prepare material completion report after there is balance between
Completion Report withdrawn, installed and excess material, attached with all required
documents (material transfer in/out, ex-used material report,
material lost charge, etc)
Material Team
SPK
owner/representative
Update material • Update material database both in contractor and client’s system base
database on the result of material completion report
• Send the original material completion report to document control for
SPK close out process
Material Team